Flush-Mounted Housing Thread Forming via Plastic Deformation
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Solution Overview
Problem
Existing methods for creating threads in ceiling or wall installation housings are costly, material-intensive, and prone to structural weaknesses due to machining or the use of additional parts, often requiring multiple processing steps and increasing manufacturing costs.
Innovation Solution
A one-piece metal installation housing with a thread formed by pressing a bead into the wall element, allowing for a simple, cost-effective production process with reduced material usage and fewer processing steps, ensuring uniform wall thickness and stable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If threads are created by machining the workpiece, then a thread is formed in the mounting housing, but the material in the thread area is weakened and additional processing steps are required
Solution Approach 1:
The patent changes the manufacturing method from subtractive machining to additive forming. The thread is created by plastic deformation of the metal wall element using a forming tool that presses the material into the threaded shape, transforming the material state rather than removing it. This preserves material strength while forming the thread.
Solution Approach 2:
The patent replaces the mechanical machining system (cutting tools, lathes, mills) with a forming system that uses controlled plastic deformation. Instead of cutting away material to create threads, a forming tool presses and shapes the metal wall element into the desired thread profile, eliminating the need for additional deburring and finishing operations.
2Ease of manufacture
If threaded inserts are used to provide a thread, then a thread is formed in the mounting housing, but manufacturing costs and labor significantly increase
Solution Approach 1:
The patent merges the thread formation process directly into the mounting housing manufacturing. The thread is formed as an integral part of the housing wall element through plastic deformation, eliminating the need for separate threaded insert components. This consolidation reduces part count, assembly steps, and manufacturing complexity.
Solution Approach 2:
The metal wall element serves multiple functions: it provides the structural housing wall, and simultaneously forms the threaded connection feature through plastic deformation. This multi-functionality eliminates the need for separate threaded inserts and reduces the overall component count and assembly complexity.
3Ease of manufacture
If sheet metal strips are inserted as threads, then a thread is provided in the mounting housing, but uniform pitch cannot be guaranteed and rework is required
Solution Approach 1:
The patent replaces the sheet metal strip insertion method with direct plastic forming of the metal wall element. The forming tool directly shapes the material in place, ensuring precise and uniform thread pitch through controlled deformation rather than relying on pre-formed strips that may vary in pitch uniformity.
Solution Approach 2:
The patent changes the thread formation approach from inserting pre-formed elements to in-situ plastic deformation. By controlling the forming process parameters (pressure, tool geometry, deformation rate), uniform thread pitch is achieved directly during manufacturing without requiring subsequent rework or quality adjustments.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces material costs and processing steps, provides stable and uniform thread formation, and allows for flexible modification in small production lines, ensuring effective sliding and guiding properties for the cover while maintaining structural integrity.
Implementation Method 1
the groove (5) is formed with a gradually increasing or decreasing depth in the beginning and end areas
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to ceiling or wall-mounted housings (1) for receiving a light source, comprising a base element (2), a wall element (3) adjoining the base element (2), and a support element (4) formed opposite the base element (2) and extending from the wall element (3) on the side facing away from the base element (2), wherein the wall element (3) has a thread at least on its inner side. The thread is pressed directly into the wall element (3) of the mounting housing (1) from the outside as a groove (5) and extends into the inner wall side as a bead (6).